Fastening system

ABSTRACT

A mechanical fastening system having an engaging component and a receiving component. The receiving component has a first bond line, a second bond line, a bond zone, and a plurality of consecutive sweep regions. The second bond line is disposed adjacent to the first bond line such that a portion of the second bond line overlaps a portion of the first bond line. The bond zone circumscribes the first bond line and the second bond line. The plurality of consecutive sweep regions are disposed within the bond zone. At least one sweep region includes a portion of both the first bond line and the second bond line, and the remaining sweep regions include at least a portion of the first or the second bond lines. The receiving component has a bond ratio greater than or equal to about 1 and less than or equal to about 20.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. §120 to, U.S. patent application Ser. No. 14/063,330, filed onOct. 25, 2013, which is a continuation of, and claims priority under 35U.S.C. §120 to, U.S. patent application Ser. No. 13/754,978, filed onJan. 31, 2013, now U.S. Pat. No. 8,590,119, which is a continuation of,and claims priority under 35 U.S.C. §120 to, U.S. patent applicationSer. No. 13/009,879, filed on Jan. 20, 2011, now U.S. Pat. No.8,388,596, which is a divisional of, and claims priority under 35 U.S.C.§120 to, U.S. patent application Ser. No. 11/710,216, filed on Feb. 23,2007, now U.S. Pat. No. 7,895,718, which claims priority under 35 U.S.C.§119(e) to U.S. Provisional Patent Application Ser. No. 60/776,326,filed on Feb. 24, 2006, and the entire disclosures of which are herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention pertains to fastening systems. Specifically, thepresent invention pertains to receiving components for use inconjunction with suitable engaging components in a fastening system.

This invention was made pursuant to a joint research agreement betweenThe Procter & Gamble Company and Mitsui Chemicals Inc.

BACKGROUND OF THE INVENTION

Refastenable mechanical fastening systems can be used in a wide numberof applications. For example, such refastenable fastening systems can beused to connect one portion of a disposable absorbent article to anotherportion of the disposable absorbent article.

In general, mechanical fastening systems comprise a receiving/femalecomponent and an engaging/male component. In some mechanical fasteningsystems, the engaging member comprises a plurality of hook elements, andthe receiving component comprises a plurality of loop elements. In afastened state, the hook elements typically are entangled with the loopelements such that a connection between the engaging and receivingcomponents is formed.

Nonwoven webs are known in the art as potential materials for use as thefemale component. Typically, a nonwoven female component comprises aplurality of polymeric fibers. Portions of these fibers can be joinedtogether by fiber-to-fiber bonds to form a web having sufficientavailable unbonded fibers or unbonded portions of bonded fibers and webintegrity. The fiber-to-fiber bonds are typically formed by fusingportions fibers together via, for example, heat, pressure, or sound(i.e., ultrasonic) energy.

In some processes a pair of heated calendering rolls can be used tocreate these fiber-to-fiber bonds. Typically, one of the calenderingrolls comprises a plurality of protrusions which extend outward from itsouter surface. A constant force is generally applied to one of thecalendering rolls such that as the nonwoven web passes between thecalendering rolls, the protrusions apply pressure to the nonwoven web.In general, at the location of applied pressure, at least onefiber-to-fiber bond is created.

In general, nonwoven webs which are to be used as receiving componentsare not completely bonded, e.g. 100% fiber-to-fiber bonds. Because thefiber-to-fiber bonds typically render the bonded areas unengageable byan engaging component, bonding the nonwoven web completely can yield apoorly performing receiving component. Therefore, the protrusionsextending outward from the outer surface of the calendering roll aretypically spaced apart such that a particular bonding pattern is createdin the nonwoven.

Additionally, it may be desirable to have large, open, unbonded areas toassure that wherever a hook from the engaging component is placed anunbonded fiber or an unbonded portion of a bonded fiber is available toengage the hook. However, a bond pattern creating large, open, unbondedareas can have reduced strength in a cross machine direction because ofthe reduced number of fiber-to-fiber bonds in the unbonded areas. Tocompensate, some bond patterns can create fully enclosed areas e.g.fully bonded fibers surrounding unbonded fibers. However, a bond patternwhich creates fully bonded fibers surrounding unbonded fibers can reducethe likelihood that a hook from an engaging component will find anunbonded fiber with which it can engage.

Additionally, the bond pattern can negatively impact the quality of thefiber-to-fiber bonds. For, example because conventional bond patterns donot completely bond the nonwoven web, the pressure applied to thenonwoven web as the nonwoven web passes through the calendering rollscan fluctuate. In some cases, the pressure fluctuations can cause higherpressures at some fiber-to-fiber bond sites and cause lower pressures atother fiber-to-fiber bond sites. The higher pressure can result inoverbonding or even cutting through fibers (which weakens the resultingweb). The lower pressure may result in a reduced percentage of bondedarea being formed compared to the desired percentage of bonded area,lower bond strength and/or lower bond quality. Additionally, the lowerpressure may cause reduced strength in the cross machine direction.

Consequently, there is a need to provide a fastening system whichincludes a receiving component having a bond pattern which reduces thepressure fluctuations experienced by the receiving component duringprocessing while maintaining sufficient areas of unbonded fibers and/orunbonded portions of bonded fibers.

SUMMARY OF THE INVENTION

The present invention pertains to a mechanical fastening systemcomprising an engaging component and a receiving component. The engagingcomponent comprises a plurality of engaging elements. The receivingcomponent has a longitudinal axis and a lateral axis, wherein theplurality of engaging elements are capable of engaging the receivingcomponent.

The receiving component further comprises a first bond line, a secondbond line, a bond zone, and a plurality of consecutive sweep regions.The first bond line and second bond line extend in a first direction,wherein the second bond line is disposed adjacent to the first bond linesuch that a portion of the second bond line overlaps a portion of thefirst bond line. The overlap is generally parallel to a second directionwhich is generally perpendicular to the first direction.

The bond zone circumscribes the first bond line and the second bondline. The plurality of consecutive sweep regions is disposed within thebond zone. Each sweep region extends in a direction generally parallelto the longitudinal axis, and each sweep region comprises a length and awidth. The lengths of the sweep regions are equal, and the widths of thesweep regions are equal. At least one sweep region comprises a portionof both the first bond line and the second bond line, wherein theremaining sweep regions of the plurality of sweep regions comprise atleast a portion of the first bond line or at least a portion of thesecond bond line. Each sweep region has a bonded area, and the receivingcomponent has a bond ratio between two sweep regions which is greaterthan or equal to about 1 and less than or equal to about 20.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an elevation view showing a fastening system constructed inaccordance with the present invention.

FIG. 1B is a plan view showing a receiving component of the fasteningsystem of FIG. 1A, the receiving component being constructed inaccordance with the present invention.

FIG. 2A is a schematic view showing a process for producing bondingpatterns in accordance with the present invention.

FIG. 2B is an elevation view showing a side of a pair of calenderingrolls of the process of FIG. 2A.

FIG. 2C is a plan view showing a receiving component constructed inaccordance with the present invention.

FIG. 3 is a plan view showing the receiving component of FIG. 1highlighting additional features of the bonding pattern.

FIGS. 4A and 4B are plan views showing other embodiments of receivingcomponents having bond patterns which are in accordance with the presentinvention.

FIG. 4C is a close up view showing a section of the web of fibrousmaterial of FIG. 4A.

FIG. 4D is a close up view of showing a section of the receivingcomponent of FIG. 1.

FIGS. 5A-5E are plan views showing repeating units various embodimentsfor repeating units which can be included in a bond pattern constructedin accordance with the present invention.

FIG. 6 is a plan view showing another embodiment of a receivingcomponent constructed in accordance with the present invention.

FIG. 7A is a perspective view showing a disposable absorbent articleconstructed in accordance with the present invention.

FIG. 7B is a plan view showing the disposable absorbent article of FIG.7A in a flattened-out uncontracted state.

FIG. 7C is an elevation view showing another embodiment of a side panelof the disposable absorbent article of FIG. 7A.

FIG. 8A is an elevation view showing a portion of the disposableabsorbent article of FIG. 6 having its fastening system in a fastenedstate.

FIG. 8B is an elevation view showing a portion of the disposableabsorbent article of FIG. 7 having its fastening system in a fastenedstate, wherein a receiving component of the fastening system is disposedon the disposable absorbent article to provide a visual alignment aid.

FIG. 9A is a close up view showing an embodiment of a composite fiber.

FIG. 9B is a close up view showing an embodiment of a composite fiber.

FIG. 9C is a close up view showing an embodiment of a composite fiber.

DETAILED DESCRIPTION OF THE INVENTION Definitions

As used herein, the terms “absorbent article” and “article” refer to awearable device that absorbs and/or contains liquid and, morespecifically, refers to a device that is placed against or in proximityto the body of the wearer to absorb and contain the various exudatesdischarged from the body. Suitable examples include diapers, trainingpants, refastenable pants, pull-on garments, adult incontinence productsand feminine care products such as sanitary napkins. Furthermore, theterms “absorbent article” and “article” include a “disposable absorbentarticle” which is intended to be discarded and not laundered orotherwise restored after no more than ten uses, preferably after no morethan five uses, and most preferably after a single use (although certaincomponents may be recycled, reused, or composted).

“Body-facing”, “wearer-facing”, “outer-facing”, and “garment-facing”,refer respectively to the relative location of an element or a surfaceof an element or group of elements. “Body-facing” and “wearer facing”imply the element or surface is nearer to the wearer during wear thansome other element or surface. “Garment-facing” and “outer facing” implythe element or surface is more remote from the wearer during wear thansome other element or surface (i.e., element or surface is proximate tothe wearer's garments that may be worn over the disposable absorbentarticle).

As used herein, the term “bond line” refers to a plurality of sites on asubstrate where the fibers of the substrate have been fused together.The plurality of sites can be fused together to form the “line”.However, the term “line”, as used herein, can also describe a series ofdiscrete points or short lines closely spaced so as to effectivelyapproximate a line. Therefore, those skilled in art will recognize thatalthough a solid line bonding pattern is described, the benefits of thepresent invention can similarly be achieved by closely spaced points ordiscrete line segments which effectively approximate a line.

As used herein, the term “bond line pattern” refers to at least two bondlines which have some overlap between the at least two bond lines.

As used herein the term “consecutive” means following one after another.For example, adjacent sweep regions of the present invention may shareboundaries with one another.

As used herein, the term “crimp” refers to a characteristic of a fiberhaving at least one fold or ridge. The term “crimp” includes fiberswhich have multiple folds, fibers which have curls, and/or fibers whichform a spiral or helical structure.

As used herein, the term “diaper” refers to an absorbent articlegenerally worn by infants and incontinent persons about the lower torsoso as to encircle the waist and legs of the wearer and that isspecifically adapted to receive and contain urinary and fecal waste. Asused herein, term “diaper” also includes “pants” which is defined below.

As used herein “elastically extensible” refers to characteristics ofextensible materials that have the ability to return to approximatelytheir original dimensions after a force that extended the extensiblematerial is removed. Herein, any material or element described as“extensible” may also be “elastically extensible” unless otherwiseprovided.

As used herein the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element to anintermediate member(s) which in turn are affixed to the other element.

The term “longitudinal” is used herein to refer to a direction which isgenerally parallel to the longest edge of an element except whereotherwise noted. In the context of disposable absorbent articles, a“longitudinal” direction runs substantially perpendicular from a waistedge to an opposing waist edge of the article and generally parallel tothe maximum linear dimension of the article. Directions within ±45degrees of the longitudinal direction are considered to be“longitudinal”.

The term “lateral” refers to a direction running generally perpendicularto and in the same plane as the “longitudinal” direction. In the contextof disposable absorbent articles, a “lateral” direction runs from onelongitudinal edge of the article to an opposing longitudinal edge of thearticle. Directions within ±45 degrees of the lateral direction areconsidered to be “lateral”.

The terms “machine direction” or “MD” refer to a direction which isgenerally parallel to the forward direction of a material, member,element, item, component, etc. through a process. For example, nonwovensare typically formed with a machine direction that corresponds to thelong or rolled direction of fabrication. The machine direction can alsobe the primary direction of fiber orientation in the nonwoven.

The terms “cross machine direction” or “CD” refer to a direction whichis generally perpendicular to and in the same plane as the machinedirection.

The terms “pant”, “training pant”, “closed diaper”, “pre-fasteneddiaper”, and “pull-on diaper”, as used herein, refer to disposablegarments having a waist opening and leg openings designed for infant oradult wearers. A pant can be configured such that the pant has a closedwaist and leg openings prior to being donned on the wearer, or the pantcan be configured such that the waist is closed and the leg openingsformed while on the wearer. A pant may be preformed by any suitabletechnique including, but not limited to, joining together portions ofthe article using a refastenable fastening system. A pant may bepreformed anywhere along the circumference of the article (e.g., sidefastened, front waist fastened, rear waist fastened). Examples ofsuitable pants are disclosed in U.S. Pat. No. 5,246,433; U.S. Pat. No.5,569,234; U.S. Pat. No. 6,120,487; U.S. Pat. No. 6,120,489; U.S. Pat.No. 4,940,464; U.S. Pat. No. 5,092,861; U.S. Pat. No. 5,897,545; U.S.Pat. No. 5,957,908; and U.S. Patent Publication No. 2003/0233082 A1.

DESCRIPTION

Fastening systems constructed in accordance with the present inventioncomprise receiving components which can reduce the pressure fluctuationswhich can occur when producing the receiving component. Specifically,receiving components constructed in accordance with the presentinvention comprise a bond pattern which can reduce the pressurefluctuations experienced by the receiving component during processing.Additionally, a receiving component constructed in accordance with thepresent invention can maintain a sufficient area of unbonded fibersand/or unbonded portions of bonded fibers such that the receivingcomponent can be used with suitable engaging components in a fasteningsystem.

As shown in FIG. 1A, a fastening system 10 constructed in accordancewith the present invention may comprise an engaging component 12 and areceiving component 100. The engaging component 12 may comprise aplurality of hooks 14 which extend outward from an engaging surface 16.The receiving component 100 may comprise a plurality of looped fibers(not shown) which are capable of becoming entangled with the pluralityof hooks 14 of the engaging component 12. Examples of suitable engagingcomponents are discussed hereafter.

The fastening system 10 can be utilized in a variety of consumer andcommercial goods which may benefit from having the fastening system ofthe present invention. Some examples of articles which can utilize thefastening system of the present invention include disposable absorbentarticles, body wraps, packaging, and industrial connections for abrasivepads, medical products, and the like.

As shown in FIG. 1B, the receiving component 100, constructed inaccordance with the present invention, may comprise a plurality of bondlines, a bond zone 130, and a plurality of consecutive sweep regions. Insome embodiments, the receiving component 100 may comprise a first bondline 110, a second bond line 112, and a third bond line 114. Embodimentshaving more than three bond lines and less than three bond lines arecontemplated.

The first bond line 110, in some embodiments, can be disposed adjacentto a first end edge 151 and the second bond line 112 can be disposedadjacent to the first bond line 110. The third bond line 114, in someembodiments, can be disposed adjacent to a second end edge 152 andadjacent the second bond line 112. In some embodiments, the first endedge 151 and the second end edge can extend from a first longitudinaledge 170 to a second longitudinal edge 172 in a direction generallyparallel to a lateral axis 162.

As shown, in some embodiments, the first bond line 110, the second bondline 112, and the third bond line 114, can extend in a first direction1222 from a first longitudinal edge 170 to a second longitudinal edge172 of the receiving component 100. In some embodiments, the firstdirection 1222 can be generally parallel to the lateral axis 162. Thefirst longitudinal edge 170 and the second longitudinal edge 172 canextend between the first end edge 151 and the second end edge 152 in adirection generally parallel to a longitudinal axis 160.

The receiving component 100 further comprises the bond zone 130. Thebond zone 130 circumscribes more than one bond line. For example, asshown, the bond zone 130 can circumscribe the first bond line 110 andthe second bond line 112. The bond zone 130, in some embodiments, maycomprise a rectangle which contacts the outermost points of the firstbond line 110 and the outermost points of the second bond line 112. Insome embodiments, the outermost points of the first bond line 110 arethose points on the first bond line 110 which are nearest the first endedge 151, nearest the first longitudinal edge 170, and nearest thesecond longitudinal edge 172. Similarly, in some embodiments, theoutermost points of the second bond line 112 are those points on thesecond bond line 112 which are nearest the second end edge 152, thefirst longitudinal edge 170, and the second longitudinal edge 172. Insome embodiments, the third bond line 114 can overlap into the bond zone130 adjacent a second boundary 134 of the bond zone 130. In someembodiments, additional bond lines may overlap into the bond zone 130either adjacent to a first boundary 132 or adjacent to the secondboundary 134.

A plurality of consecutive sweep regions 140, 142, 144, and 146, can bedisposed within the bond zone 130. A sweep region comprises a portion ofthe receiving component 100 and is used to analyze the bonded area andtotal area of the portion of the receiving component 100 within thatsweep region. An advantage of sweep regions with smaller lengths 175 isthat essentially more data points on the bond lines can be collected.The higher number of data points can increase the accuracy of thecalculation of the variability in the bonded area in the receivingcomponent 100. The cumulative lengths 175 of the sweep regions 140, 142,144, and 146, are equal to the length of the bond zone 130.

Each sweep region 140, 142, 144, and 146, comprises a portion of thefirst bond line 110 and/or the second bond line 112. In someembodiments, some of the consecutive sweep regions 140, 142, 144, and146, may comprise portions of additional bond lines which overlap intothe bond zone 130 either adjacent to the first end edge 151 or thesecond end edge 152. For example, because the third bond line 114overlaps the bond zone 130, the sweep region 146 may further comprise aportion of the third bond line 114.

At least one sweep region comprises a portion of both the first bondline 110 and the second bond line 112. For example, as shown, in someembodiments, two sweep regions, i.e. 142 and 144, comprise a portion ofthe first bond line 110 and the second bond line 112. Depending on thesizes of the sweep regions, one or more sweep regions may compriseportions of more than one bond line. Embodiments comprising more thanfour sweep regions and fewer than four sweep regions are contemplated.

Because the sweep regions 140, 142, 144, and 146, are consecutive, eachsweep region shares a boundary with an adjacent sweep region. Forexample, sweep region 140 shares a boundary with sweep region 142.Similarly, sweep region 144 shares a boundary with sweep region 142.However, the sweep regions 140, 142, 144, and 146, are arranged suchthat the odd (first and third) sweep region, e.g. 140 and 144 do notshare a boundary. Additionally, the sweep regions 140, 142, 144, and146, are arranged such that the even (second and fourth) sweep regions,e.g. 142 and 146, do not share a boundary.

The consecutive sweep regions 140, 142, 144, and 146, are rectangularand extend from the first longitudinal edge 170 to the secondlongitudinal edge 172 of the receiving component 100. The consecutivesweep regions 140, 142, 144, and 146, have a width 177 which can beequal to a width of a web of fibrous material which the receivingcomponent may comprise. The width 177 can be generally parallel to thelateral axis 162. In some embodiments, the sweep regions 140, 142, 144,and 146, can have the length 175 which is equal to a contact length 250(shown in FIG. 2B) between calendering rolls. In some embodiments, thesweep regions 140, 142, 144, and 146, can have the length 175 which isless than the contact length 250 (shown in FIG. 2B). In someembodiments, the length 175 can range from about 0.1 mm to about 1.2 mmor any individual number within the range. The length 175 can begenerally parallel to the longitudinal axis 160.

Each of the sweep regions 140, 142, 144, and 146, comprises the length175 which is equal to the length 175 of adjacent sweep regions.Additionally, as shown, in some embodiments, the sweep region 140 mayshare the first boundary 132 with the bond zone 130. Also, in someembodiments, the sweep region 146 can share the second boundary 134 withthe bond zone 130.

Each sweep region 140, 142, 144, and 146, comprises a bonded area whichis defined by the bonding pattern. The percentage bonded area in a sweepregion is a measure of the fiber-to-fiber bonds within the sweep region.Specifically, the percentage bonded area is determined by calculatingthe area of the fiber-to-fiber bonds within a particular sweep region,and dividing this area by the total area in the sweep region andmultiplying by 100.

The bonded areas of the sweep regions 140, 142, 144, and 146, can vary.The variability of the amount of the bonded areas among the sweepregions 140, 142, 144, and 146, can be determined by comparing a valueof a sweep region having the largest bonded area to a value of a sweepregion having the lowest bonded area. A ratio of the largest bonded areaof a sweep region and the lowest bonded area of a sweep region is termedthe bond ratio. In some embodiments, the bond ratio is greater than orequal to about 1 and less than about 20 or any individual number withinthe range. In other embodiments, the bond ratio is greater than or equalto about 1 and less than or equal to about 10. In other embodiments, thebond ratio is greater than or equal to about 1 and less than or equal toabout 3. In some embodiments, where the bond ratio is 1, there may notbe a value of the largest bonded area or a value of the lowest bondedarea. In this instance, the value of one bonded area can be divided bythe value of another bonded area.

Adding the bonded areas of each of the individual sweep regions canprovide the cumulative bonded area. Adding the total areas of each ofthe individual sweep regions can provide the cumulative total area.Dividing the cumulative bonded area by the cumulative total area canprovide the overall bonded area of the bond zone 130, in someembodiments, or the overall bonded area of the receiving component 100in other embodiments.

As shown in FIGS. 2A and 2B, the bond lines, e.g. 110 (shown in FIG.1B), 112 and 114, of a receiving component 100 (shown in FIG. 1), insome embodiments, can be produced via a calendering system 200. Thecalendering system 200 may comprise a pair of calendering rolls 202 and204 which create a nip therebetween. The outer surface of the calenderroll 202 and/or the calender roll 204 may comprise protrusions (notshown) extending outward from their outer surface. These protrusionstypically create fiber-to-fiber bonds in a web of fibrous material 275as the web of fibrous material 275 passes through the nip. The receivingcomponent 100 (shown in FIGS. 1A and 1B) may comprise a portion of theweb of fibrous material 275.

The web of fibrous material 275 can pass through the calendering rolls202 and 204 in a direction generally parallel to the longitudinal axis160 (shown in FIG. 1B) of the receiving component 100 (shown in FIGS. 1Aand 1B). Specifically, the longitudinal axis 160 (shown in FIG. 1B) ofthe receiving component 100 (shown in FIGS. 1A and 1B) can be generallyparallel to a machine direction of the calendering system 200. Thecalendering rolls 202 and 204 can rotate in direction shown by arrows280 and 281 (shown in FIG. 2B), respectively.

In some embodiments, the calendering rolls 202 and/or 204 can be heated.The calendering rolls 202 and 204 can provide energy to the web offibrous material 275 as the web of fibrous material 275 passes throughthe nip. Additionally, in some embodiments, a force 240 can be appliedto the calendering rolls 202 and/or 204 such that a pressure is appliedto the web of fibrous material 275 as it passes through the nip. Theforce 240 which can be applied to the calendering rolls 202 and/or 204is discussed hereafter.

The surface to surface contact of the calendering rolls 202 and 204 candefine the contact length 250. The contact length 250 is defined by aportion of the calender roll 202 and a portion of the calender roll 204which are in contact with the web of fibrous material 275 (shown in FIG.2A) as the web of fibrous material 275 (shown in FIG. 2A) passes throughthe nip. In some embodiments, the contact length 250 can be determinedvia the Hertzian equation below.

The Hertzian equation assumes that the calendering rolls 202 and 204 aremade from homogeneous, isotropic material, and further assumes thevalidity of Hooke's law. Other assumptions include that the calenderingrolls 202 and 204 have equal diameters; that the calendering rolls 202and 204 are created from material which has the same elastic modulus;and that the width 220 of the calendering rolls 202 and 204 are at leastas wide as the width 177 (shown in FIG. 1B) of the sweep regions. Thecontact length 250 can be found via the following equation:

$X = \sqrt{\frac{8{{FR}\left( {1 - v^{2}} \right)}}{\pi \; {EL}}}$

where

X is ½ the width of the contact area 250;

R is the radius of the calender roll 202 or 204 in millimeters;

F is the force applied in Newtons/mm;

E is the elastic modulus of the material of the calender rolls 202 and204;

L is the width of the calender rolls 202 and 204 (as shown 220); and

ν is Poisson's ratio.

Where the calendering rolls do not have equal diameters, one skilled inthe art could rederive the above equation taking into account theunequal diameters of the calendering rolls. Where the calendering rollsare not made from materials which have equal elastic moduli, one skilledin the art could rederive the above equation taking into account theunequal elastic moduli of the calendering rolls.

In some embodiments, where the calendering rolls are made of steel, theelastic modulus E can be equal to 210,000 N/mm², Poisson's ratio can be0.3, and applied force F can be between about 30 N/mm to about 150 N/mm.As mentioned above, X is equal to ½ of the contact length 250. Thus,multiplying X by two provides the contact length 250. In someembodiments, the contact area 250 can be in a range from about 0.1 mm toabout 1.2 mm or any individual number within the range. In someembodiments, the contact area 250 can be in a range from about 0.7 mm toabout 1.0 mm.

One advantage of the present invention is that because of the ratio oflarger bonded area to lesser bonded of the present invention, pressurefluctuations during the calendering process can be reduced. For example,in conventional receiving components where bond areas vary among sweepregions by more than 2000%, the contact area of the calendering rollsproducing these bonded areas varies by more than 2000% also.Consequently, if the force applied to the calender rolls is constant,the pressure applied to a web of fibrous material as it passes throughthe nip of the calender rolls varies by more than 2000% as well. Inconventional receiving components pressure fluctuations of greater than2000% can occur when some sweep regions comprise a 0% bonded area,thereby yielding a ratio of larger bonded area to lesser bonded areawhich is infinite. The zero percent bonded area can occur, for example,when a first bond line and a second bond line are separated by a finitedistance in a direction generally parallel to the longitudinal axis ofthe receiving component which is equal to at least the length of a sweepregion. As another example, pressure fluctuations of greater than 2000%can also occur where there is too much overlap between bond lines or toolittle. The overlap between bond lines is discussed further with regardto FIG. 3.

From a process perspective, the pressure fluctuations of greater than2000% can cause process instabilities. For example, the extreme pressurefluctuations can cause premature failure of the protrusions on thecalender rolls.

From a product/material performance perspective pressure fluctuations ofgreater than 2000% are also not typically desirable. For example, asweep region having 0% bonded area can provide low shear capability andpotentially poor refastenability results. Specifically, because lessloose fiber ends are bonded within this sweep region, fuzzing can resultduring multiple opening and closing cycles with suitable engagingcomponents.

Also, sweep regions having 0% bonded area can reduce the strength in adirection parallel to a lateral axis of the receiving component. Thelateral axis of the receiving component, in some embodiments can beassociated with the direction of shear in many instances. For example,in a fastened state, the lateral axis of the receiving component can begenerally parallel to the direction of shear. For example, referring toFIG. 8A momentarily, in a fastened state, shear forces can act along aprimary direction of shear 775 which is generally parallel to a lateralaxis of a receiving component 740. Where there is no overlap betweenadjacent bond lines, the receiving component material in betweenadjacent bond lines remains free to move with the applied shear force.

In contrast, where the overlap between bond lines causes pressurefluctuations of greater than 2000%, the concentration of fiber-to-fiberbond sites in the region of overlap will generally provide poorfastenability results. For example, as stated previously, engagingcomponents generally are not able to engage receiving components at thebonded areas.

Additionally, the pressure fluctuations of greater than 2000% can alsocause variable bonding quality, as discussed previously. When pressurefluctuations are greater than 2000%, fiber-to-fiber bonds in the lesserbonded area sweep regions experience higher pressure than larger bondedarea sweep regions and can incur holes because of the higher pressure.Also, the fiber-to-fiber-bonds in the larger bonded area sweep regionscan experience lower pressure than lesser bonded area sweep regions andcan incur less fiber-to-fiber bonds because of the lower pressure.Specifically, the lower pressure, in some cases, can merely compressfibers instead of actually bonding them.

As shown in FIG. 2C, a receiving component 30 was constructed inaccordance with the present invention and incurred some defects, e.g.32, 34, 36, 38, 40, and 42. The bond ratio in the receiving component 30was about 1.8. It is believed that at ratios of about 20 or less, anacceptable number of defects may exist. However, for bond ratios above20 an unacceptable amount of defects would occur in a receivingcomponent and therefore be outside the range of the present invention.

In contrast, with conventional receiving components, a receivingcomponent constructed in accordance with the present invention reducespressure fluctuations below about 2000%. The reduction in pressurefluctuation, in part, is accomplished by assuring that a bond area ofthe receiving component comprises a plurality of sweep regions whicheach have some finite amount of bonded area. Additionally, the sweepregions for receiving components constructed in accordance with thepresent invention comprise bonded area percentages which reduce pressurefluctuations below about 2000%.

There are several factors which can impact the ratio of larger bondedarea to lesser bonded area. Some factors include the overlap of the bondlines, in some embodiments, the orientation angle of the bond lines, theperiod of the bond lines, and in some embodiments, the orientation ofthe bond lines during processing. The orientation of the bond linesduring processing is discussed further in regard to FIG. 6.

As shown in FIG. 3, the overlap 320 is a distance between a firstreference line 302 and a second reference line 304. In some embodiments,the overlap 320 is generally parallel to the longitudinal axis 160 andgenerally parallel to a second direction 1223. The first reference line302, in some embodiments, can be drawn between two inwardmost points 308and 310 on the first bond line 110 and can be generally parallel to thelateral axis 162. In some embodiments, the second reference line 304 canbe drawn between two inwardmost points 312 and 314 of the second bondline 112 and can be generally parallel to the lateral axis 162. In someembodiments, the inward most points 308 and 310 of the first bond line110 can be the points nearest the second bond line 112. Similarly, insome embodiments, the inwardmost point 312 and 314 of the second bondline 112 can be the point nearest the first bond line 110. Where thefirst bond line 110 does not intersect the second reference line 304,and where the second bond line 112 does not intersect the firstreference line 302, there is no overlap between the first bond line 110and the second bond line 112.

Additionally, FIG. 3 shows a period 330, an orientation angle 350, bondline spacing 370, and a bond line thickness 360. In some embodiments,the period 330 can be the smallest interval after which a periodicfunction takes the same values. As shown, in some embodiments, theperiod 330 can be a distance from a first peak 332 of the third bondline 114 to a second peak 334 of the third bond line 114. In embodimentswhere the first bond line 110 and the second bond line 112 are similarto the third bond line 114, the period 330 can be found similarly forthe first bond line 110 and the second bond line 112. An orientationangle 350, where a portion of the first bond line 110 intersects thefirst reference line 302, is also shown.

The bond line spacing 370 is the distance between the first and secondbond lines 110 and 112. For example, in some embodiments, the bond linespacing 370 can be measured from the inwardmost point 308 of the firstbond line 110 to the outward most point 372 on the second bond line 112.The outwardmost point 372 on the second bond line 112, in someembodiments, can be the point nearest the third bond line 114. In someembodiments, the bond line spacing 370 can be generally parallel to thelongitudinal axis 160. Any suitable spacing can be used. For example,the spacing 370 between the bond lines can be in a range from about 1 mmto about 20 mm or any individual number within the range. As yet anotherexample, the spacing 370 can be between about 3 mm and about 18 mm. Asyet another example, the spacing 370 can be between about 6 mm and about12 mm.

Similarly, any suitable bond line thickness 360 can be utilized. Forexample, in some embodiments, the bond line thickness 360 can be in arange from about 0.2 mm to about 5 mm or any individual number withinthe range. In some embodiments, the bond line thickness 360 can be in arange from about 0.5 mm to about 2 mm. In some embodiments, the bondline thickness 360 can be in a range from about 1 mm to about 1.5 mm.

Any suitable period 330 can be used in conjunction with the presentinvention. For example, in some embodiments, the period 330 can be in arange from about 1 mm to about 20 mm or any individual number within therange. In some embodiments, the period 330 can be in a range from about1.5 mm to about 15 mm. In some embodiments, the period 330 can be in arange from about 5 mm to about 12 mm.

The effect that the overlap of the bond lines has on the ratio of largerbonded area to lesser bonded area is illustrated in Table I. Table Icontains prophetic examples, and all calculations contained in Table Iare based on a zigzag bond line pattern similar to the bond line patternshown in FIG. 1.

TABLE I Example # 1 2 3 4 5 Line Thickness (mm) 1 0.5 0.5 1 0.5orientation angle (degrees) 63.4 63.4 63.4 63.4 63.4 Period “T” (mm) 9.39.3 9.3 9.3 9.3 line spacing (mm) 6 6 12 3 3 Contact width (mm) 0.250.25 0.25 0.25 0.25 Overlap (mm) 5.52 4.4 0 8.52 7.4 Overall Area, %Bonded 37.2 18.6 9.3 74.4 37.2 Larger Area (mm{circumflex over ( )}2)1.12 0.56 0.28 1.75 0.91 Lesser Area (mm{circumflex over ( )}2) 0.560.28 0.00 1.68 0.84 Larger/Lesser Ratio 2.00 2.00 infinite 1.04 1.09 MaxArea, % Bonded 48.10 24.05 12.03 75.23 39.15 Min Area, % Bonded 24.0612.03 0.00 72.16 36.08 Max/Min Ratio (%/%) 2.00 2.00 infinite 1.04 1.09

As shown in Table I and as discussed previously (see Example 3), wherethe overlap of the bond lines is equal to zero, the ratio of largerbonded area to lesser bonded area can be infinite in some instances. Incontrast, in the embodiments of the present invention, the first bondline 110 (shown in FIG. 1) and the second bond line 112 (shown inFIG. 1) overlap one another by a finite amount. As shown, see Example 1and 4, as the overlap increases, the ratio of larger area to lesser areadecreases.

The overlap can be impacted by the thickness of the bond lines. Forexample, in Table I, as the thicknesses of the bond lines decrease, theoverlap between the bond lines can similarly decrease (see Example 1 and2). Additionally, the thickness of all the bond lines in one pattern canbe changed as desired to adjust the overall percent bonded area of thebond pattern. Similarly, the overlap can be impacted by the spacing ofthe bond lines. For example, in Table I, as the spacing between the bondlines increase, the overlap between the bond lines decreases (seeExamples 1 and 4; 2 and 5).

The effect that the orientation angle 350 has on the ratio of largerbonded area to lesser bonded area is illustrated in Table II. Table IIcontains prophetic examples, and all calculations contained in Table IIare based on a zigzag bond line pattern similar to the bond line patternshown in FIG. 1.

TABLE II EXAMPLE #: 6 7 8 9 10 11 Line Thickness (mm) 1 1 1 1 1 1Orientation Angle (degrees) 75 65 60 55 45 65.082 Period (mm) 9.3 9.39.3 9.3 9.3 9.3 Line Spacing (mm) 18.7 9.8 7.53 5.86 3.54 10.01 ContactLength (mm) 0.5 0.5 0.5 0.5 0.5 0.5 Overlap (mm) 2.52 2.54 2.52 2.522.52 2.37 Lesser bonded area (%) 14.51 23.73 24.83 26.25 30.41 23.71Larger bonded area (%) 22.26 25.45 31.34 38.01 53.87 23.71 RatioLarger/Lesser 1.53 1.07 1.26 1.45 1.77 1.00 Overall Area % Bonded 20.724.1 25.0 29.8 30.7 23.71

For the examples shown above, the orientation angle 350 (shown in FIG.3) is changed for a zigzag bond pattern similar to the bond patternshown in FIG. 1. As shown, the orientation angle 350 (shown in FIG. 3)was manipulated from about 75 degrees to about 45 degrees, whilemaintaining an overlap of about 2.5 mm for most examples. In order toensure an equal amount of overlap for most examples, the line spacingwas also varied for each orientation angle 350 (shown in FIG. 3). Insome examples, the period and the bond line thickness were keptconstant.

In example 6, the orientation angle is at 75 degrees, resulting in thelowest overall percentage bonded area of 20.7% compared to the otherexamples in Table II. Without wishing to be bound by theory, it isbelieved that as the overlap remains constant at about 2.5 mm, this lowpercentage bond area is the consequence of the line spacing of 18.7 mm,the line thickness of 1 mm, and the period of 9.3 mm.

As shown in example 7, at an orientation angle of 65 degrees, whilemaintaining the overlap at 2.5 mm, the total percentage of bonded areacan increase to 24.1% at a line spacing of 9.8 mm. The reduction in theorientation angle by about 10 degrees from example 6 can reduce theratio of larger bonded area to lesser bonded area from 1.53 to 1.07.

In accordance with the present invention, the orientation angle 350, insome embodiments, can range from about 45 degrees to about 75 degrees orany individual number within the range. In other embodiments, theorientation angle 350 can range from about 55 degrees to about 65degrees. In yet other embodiments, the orientation angle 350 can rangefrom about 60 to about 65 degrees.

Example 11, illustrates, in one particular embodiment, how the ratio oflarger to lesser bonded area can be made to equal 1.0 for a zigzag bondline pattern similar to that shown in FIG. 1. In some embodiments, theratio of larger to lesser bonded area can be equal to about 1.0 byadjusting the bond line thickness in the areas where the bond lines donot overlap. Based on the parameters and the relationships of thoseparameters discussed herein, the modification of at least one of theparameters and/or a relationship between parameters to achieve the ratioof larger bonded area to lesser bonded area of about 1.0 iscontemplated.

The effect that the period has on the ratio of larger bonded area tolesser bonded area is illustrated in Table III. Table III containsprophetic examples, and all calculations contained in Table III arebased on a zigzag bond line pattern similar to the bond line patternshown in FIG. 1.

TABLE III Example # 12 13 14 15 16 17 18 19 20 Line Thickness (mm) 1 1 11 1 1 1 1 1 Orientation angle 60 60 60 60 60 60 60 60 60 (degrees)Period (mm) 5 6 7 8 9 8 9 10 11 Line Spacing (mm) 6.2 6.2 6.2 6.2 6.2 77.9 8.7 9.6 Contact Length (mm) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5Amplitude 3.17 3.6 4.03 4.46 4.90 4.46 4.9 5.33 5.76 Overlap (mm) 0.131.00 1.86 2.73 3.59 1.93 1.89 1.96 1.93 Lesser Area Bonded (%) 6.1619.17 30.72 28.87 25.66 27.83 24.30 22.63 20.22 Larger Area Bonded (%)46.19 38.49 32.99 39.38 46.00 28.87 25.66 23.09 20.99 Ratiolarger/lesser Area 7.50 2.01 1.07 1.36 1.79 1.04 1.06 1.02 1.04 Bonded —Overall Area Bonded 32.3 32.3 32.3 32.3 32.3 28.6 25.3 23.0 20.8 (%)

At an equal percentage of the total bonded area, the determined largerbonded area to lesser bonded area ratio is at 1.07 for a period equal toabout 7. The overlap for example 13 can be about 1.9 mm. Based on thedata in Table III, in some embodiments, the period can range from about5 mm to about 11 mm or any number within the range. In otherembodiments, the period can range from about 6 mm to about 8 mm. In yetother embodiments, the period can be about 7 mm.

As shown in examples 17-20, the bond line spacing can be adjusted suchthat overall bonded area is impacted. In some embodiments of the presentinvention, the overall bonded area can be in a range from about 10% toabout 50% or any individual number within the range. In otherembodiments, the overall percentage of bonded area can be between about20% to about 30%. In yet other embodiments, the overall percentage ofbonded area can be between about 20% to about 25%. In other embodiments,the overall bonded area can be less than about 40% while the bonded areain any sweep region is less than about 60%. In other embodiments, theoverall bonded area can be less than about 30% while the bonded area inany sweep region can be less than about 50%. In yet other embodiments,the overall bonded area can be between about 20% to about 30% while thebonded area in any sweep region is less than about 40%.

As stated previously, the data in Tables I, II, and III, are based on azigzag bond line patterns similar to the bond line pattern shown inFIG. 1. However, one skilled in the art can calculate the values for thelisted parameters in Tables I, II, and III, for any given bond linepattern or variations thereof. For example, for simple geometries, e.g.consisting of angled and connected straight lines, the values shown inTables I, II, and III, can be calculated using the geometric andtrigonometric relationships of the angled and connected straight linesas done for the bond line patterns shown heretofore. For more complexpatterns, for example, those shown in FIGS. 4A-4C, or bond line patternsincluding shapes such as those of FIGS. 5B-5E, the values of Tables I,II, and III, can be obtained by utilizing computerized image analysis.

In computerized image analysis, the bond pattern in question isdigitized such that a color contrast can be reliably measured todetermine where bonded and unbonded areas are. For example, unbondedareas may be represented as white pixels and bonded areas may berepresented as black pixels. The number of pixels representing a bondedarea can be counted and compared to number of pixels representing anunbonded area to determine the percentage of bonded area. Similarly, theperiod, overlap, bond line thickness, orientation angle, and linespacing can also be measured using computerized image analysis.

Additionally, any data or trends discussed in regard to Tables I, II,and III, are pertinent to the bond line patterns analyzed, e.g. zigzagpattern. Consequently, any data and/or trends discussed regarding TablesI, II, and III, may not be valid for other bond line patterns.

As shown in FIGS. 4A-4C, the overlap between adjacent bond lines can beachieved in a number of different manners. For example, as shown in FIG.4A, a receiving component 400A constructed in accordance with thepresent invention may comprise a first bond line 410A and a second bondline 412A. The first bond line 410A and the second bond line 412A mayeach comprise a plurality of repeating units 510A. The repeating units510A of the first bond line 410A and the second bond line 412A, in someembodiments, can overlap one another via extensions 520 generallyextending in a direction parallel to the longitudinal axis 160 from eachrepeating unit 510A. Also, as shown, in some embodiments, the first andthe second bond lines 410A and 412B may comprise extensions 520 whichextend in a direction generally parallel to the longitudinal axis 160 inbetween repeating units 510A.

In some embodiments, the extensions 520 may extend at an angle withrespect to the longitudinal axis 160. In some embodiments, the extensionangle 1350 (shown in FIG. 4C) can be in a range from greater than about0 degrees to less than about 180 degrees or any individual number withinthe range. In yet other embodiments, the extension angle 1350 (shown inFIG. 4C) can be in a range of about 30 degrees and less than or equal toabout 150 degrees. In yet other embodiments, the extension angle 1350can be in a range from about 60 degrees to about 120 degrees. In someembodiments, the extension angle 1350 of all bond lines can be similar.In some embodiments, the extension angle 1350 can vary between the bondlines of a bond pattern. Additionally, in some embodiments, theextension angle 1350 can vary among repeating units 510A.

In other embodiments, as shown in FIG. 4B, a receiving component 400Bconstructed in accordance with the present invention may comprise afirst bond line 410B and a second bond line 412B. Similarly, the firstbond line 410B and the second bond line 412B may comprise a plurality ofrepeating units 510B having extensions 520. The extensions 520 of therepeating units 510B can be configured similarly to the extensions 520of the repeating units 510A. Additionally, as shown in FIG. 4B, the bondlines of the present invention are not limited to rectilinear repeatingunits 510A. For example, as shown, in some embodiments, the bond linesmay comprise a plurality of repeating units 510B comprising curvilinearsegments. As shown, the repeating units 510B appear sinusoidal innature. Examples of other repeating units are shown in FIGS. 5A-5E.

The extensions 520 of FIGS. 4A and 4B, in some embodiments, can bestraight lines as shown. However, the extensions may comprise anysuitable shape. For example, in some embodiments, the extensions 520 maycomprise rectangles, circles, triangles, rhomboid like structures,trapezoidal like structures, any suitable polygonal shape, curvilinearlines, angled lines, squiggly lines, combinations thereof, or the like.In other embodiments, the extensions 520 may comprise aesthetic designssuch as, for example, a graphic or child graphic. The graphic may be anysuitable visual image or images. The graphic may include pictorialsymbols and/or images, such as, but not limited to, photographs,drawings, embossments, or any other suitable materials utilized tocreate pictorial symbols and/or images. The pictorial symbols and/orimages may include an image of a child, an anthropomorphic image of ananimal or object, images of cartoons including well known cartooncharacters, images of well known brand logos or the like, and/or imagescharacters specifically created to be associated with the implement ofcommerce, symbols, such as, but not limited to arrows, indications ormotion or movement, and the like, and combinations thereof. Graphics andchild graphics are discussed in U.S. Patent Publication No.2005/0129743A1, U.S. Patent Publication No. 2005/0125923A1, and U.S.Patent Publication No. 2005/0125877A1.

It has been found that in some embodiments, sweep regions which compriseportions of more than one bond line can have higher bonded areas thansweep regions comprising a portion of a single bond line. The bondedarea of the sweep regions comprising portions of more than one bond linecan be reduced by any suitable means. For example, as shown in FIG. 4D,the first bond line 110 and/or the second bond line 112 may comprise aplurality of bond sites 460 which, in some embodiments, can approximatea line. The plurality of bond sites 460 can be disposed in the overlap320 of the first bond line 110 and the second bond line 112. In someembodiments, the plurality of bond sites 460 within the overlap 320 candefine less bonded area than a continuous bond line in the overlap,thereby reducing the amount of bonded area in the overlap 320. Theplurality of bond sites 460 may comprise any suitable shape known in theart.

As shown in FIG. 5A, a receiving component constructed in accordancewith the present invention may comprise a bond line which includes aplurality of repeating units 510A. The repeating unit 510A, in someembodiments, may comprise an open geometrical shape comprisingrectilinear lines which form a first leg 517 and a second leg 519 of therepeating unit 510A. As shown in FIG. 5B, in some embodiments, therepeating unit 510A may comprise rounded edges 529 which join the firstleg 517 and the second leg 519 of the repeating unit 510A. The roundededges 529 can similarly be disposed between adjacent repeating units. Asshown in FIG. 5C, the repeating unit 510A may comprise flat edges 530which join the first leg 517 to the second leg 519 of the repeating unit510A. The flat edges 530 can similarly be disposed between adjacentrepeating units.

As shown in FIG. 5D, in some embodiments, the repeating unit 510A maycomprise a plurality of wavy edges 512 and 514 which define the boundaryfor the first leg 517 and the second leg 519. In embodiments where thebond lines comprise a plurality of repeating units having wavy edges,the bond line thickness can be determined by measuring the thickness ofthe repeating unit 510A in at least 10 locations and determining theaverage thickness therefrom. Additionally, as shown in FIG. 5E, in someembodiments, the repeating unit 510B may comprise a plurality ofsinusoidal shaped edges 516 and 518.

The repeating units 510A and 510B of the present invention may compriseany suitable shape or a combination of shapes. In some embodiments, abond line of the present invention may comprise different repeatingunits within the bond line. In other embodiments, the repeating units ina first bond line may be similar while a second bond line comprises arepeating unit which is different from the repeating units of the firstbond line.

As mentioned previously, the orientation of the bond lines duringprocessing can also impact the ratio of larger bonded area to lesserbonded area. In a receiving component constructed in accordance with thepresent invention, a longitudinal axis of the receiving component can begenerally parallel to a machine direction during processing. In someembodiments, the resulting bond lines can extend from the firstlongitudinal edge 170 (shown in FIGS. 1B and 3) to a second longitudinaledge 172 (shown in FIGS. 1B and 3).

In contrast, as shown in FIG. 6, in some embodiments, a receivingcomponent 1000 constructed in accordance with the present invention maycomprise a first bond line 1010, a second bond line 1012, and a thirdbond line 1014. In some embodiments, each of the first bond line 1010,the second bond line 1012, and the third bond line 1014, can extend froma first end edge 1151 to a second end edge 1152 of the receivingcomponent 1000 in a first direction 1224 which is generally parallel toa longitudinal axis 1060. The receiving component 1000 may comprise abond zone 1030 which circumscribes a bond line nearest a firstlongitudinal edge 1170 and a bond line nearest a second longitudinaledge 1172 and any bond lines in between. For example, as shown, the bondzone 1030 can circumscribe the first bond lines 1010, the second bondline 1012, and the third bond line 1014. Embodiments are contemplatedwhere the receiving component comprises more than three bond lines andfewer than three bond lines.

The bond zone 1030 comprises a plurality of sweep regions 1040, 1042,1044, 1046, 1048, 1050, and 1052. The plurality of sweep regions 1040,1042, 1044, 1046, 1048, 1050, and 1052, may comprise similar lengths andwidths to the sweep regions discussed heretofore. As shown, in someembodiments, each sweep region of the plurality of sweep regions 1040,1042, 1044, 1046, 1048, 1050, and 1052, may comprise a portion of thefirst bond line 1010, a portion of the second bond line 1012, and aportion of the third bond line 1014.

Similar to the bond line pattern shown in FIG. 1B, in the bond linepattern of FIG. 6, each sweep region has some finite amount of bondedarea. The first bond line 1010 can overlap the second bond line 1012,and the second bond line 1012 can overlap the third bond line 1014.However, in contrast to the overlap 320 (shown in FIG. 3) of thereceiving component 100 (shown in FIGS. 1 and 3) the overlap 1020 of thereceiving component 1000 can be generally parallel to the lateral axis1062. Similarly, the second bond line 1012 can overlap the third bondline 1014.

The overlap 1020 can be the distance between a third reference line 1565and a fourth reference line 1575. In some embodiments, the overlap 1020can be generally parallel to a second direction 1225. The thirdreference line 1565, in some embodiments, can be generally parallel tolongitudinal axis 1060. Similarly, the fourth reference line 1575, insome embodiments, can be generally parallel to the longitudinal axis1060. The third reference line 1565 can extend from the first end edge1151 to the second end edge 1152 and can intersect the inwardmost pointsof the first bond line 1010. The inwardmost points of the first bondline 1010 are those points which are nearest the second bond line 1012.The fourth reference line 1575 can extend from the first end edge 1151to the second end edge 1152 and can intersect the outwardmost points ofthe second bond line 1012. The outwardmost points of the second bondline 1012, when referencing the overlap 1020 between the first bond line1010 and the second bond line 1012, are those points on the second bondline 1012 which are nearest the first bond line 1010.

A receiving component of the present invention may be configured in anumber of different manners. For example, in some embodiments, thereceiving component may comprise a web of fibrous material such as awoven web, nonwoven web, or any combination thereof. In someembodiments, the process described in regard to FIGS. 2A and 2B can beutilized to create fiber-to-fiber bonds among loose fibers of anonwoven, thereby creating a nonwoven web.

In other embodiments, the process can be utilized to providesupplemental bonding to an already lightly bonded nonwoven web.Additionally, in some embodiments, the supplemental bonding can join thenonwoven web to a support structure. For example, the nonwoven web canhave an initial bonded area of between about 10% and about 20% and cansubsequently be bonded to a support layer using the bond patterns of thepresent invention. The resulting receiving component can have a bondedarea higher than the initial bonded area.

The support layer may comprise any suitable support layer known in theart. For example, the support layer can include films or nonwoven webs.Embodiments are contemplated where the receiving component is joined toa disposable absorbent article utilizing the bond patterns of thepresent invention. For example, the receiving component can be joined toa backsheet of a disposable diaper.

One advantage of joining a receiving component to an underlying supportlayer utilizing the bond patterns of the present invention is that, insome embodiments, no adhesive is required. For example, in certainembodiments, when using a calendering system as described in regard toFIGS. 2A and 2B, the bond pattern of the present invention can beutilized to join a receiving component and a support layer withoutadhesive.

In certain embodiments, the initial bonded area of a receiving componentmay not be able to be measured. Specifically, in embodiments where thereceiving component comprises a nonwoven web having hydroentangledfibers or needle punched fibers, an initial bonded area may not beascertainable. However, these nonwoven webs can still be utilized in areceiving component and can be joined to underlying support layers usingthe bonding patterns of the present invention.

As mentioned previously, a receiving component constructed in accordancewith the present invention may comprise a nonwoven web. In someembodiments, the nonwoven web may comprise one layer of fibers. In otherembodiments, the nonwoven web may comprise more than one layer offibers. Any suitable nonwoven web can be used. For example, a suitablenonwoven may comprise fibers made of polypropylene, polyethylene,polyester, nylon, cellulose, polyamide, or combinations of suchmaterials. Fibers of one material or fibers of different materials ormaterial combinations may be used in the first and/or second nonwoven.Exemplary nonwoven materials include spunbond, spunbond meltblownspunbond (SMS), spunbond meltblown meltblown spunbond (SMMS), carded,meltblown, and the like. Particularly acceptable nonwovens include highelongation carded (HEC) nonwovens and deep activation polypropylene(DAPP) nonwovens. Any process known in the art may be used to make thenonwovens.

The nonwoven may comprise fibers that are bonded mechanically, includingfibers that are needle punched or hydro entangled. Other suitablebonding processes for producing a suitable nonwoven for use in thepresent invention are spun bonding, thermally bonding, bonding byvarious types of chemical bonding such as latex bonding, powder bonding,and the like. In certain embodiments, the basis weight of the nonwovencan be in the range of about 10 gsm to about 100 gsm or any individualnumber within the range. In other embodiments, the basis weight of thenonwoven can be in a range of about 25 gsm to about 80 gsm. In yet otherembodiments, the basis weight of the nonwoven can be in a range of about30 gsm to about 50 gsm.

The fibers may be of any suitable size and shape. Some examples ofsuitable cross sectional shapes include circular, elliptical (with orwithout lobe like extensions), rectangular, triangular, rhomboidal,trapezoidal, any polygon, or the like. Additionally, the cross sectionalshape, in some embodiments, may include a plurality of lobes. Forexample, a cross sectional shape may include three lobes, i.e. trilobal.Embodiments having more than three lobes and fewer than three lobes arecontemplated. In some embodiments, the fibers can be hollow. Forexample, the fibers may be hollow crimped fibers.

The fiber may be of any suitable denier. For example, in someembodiments, the fiber may have a denier ranging from about 1 to about10 or any individual number within the range. In some embodiments, thedenier of the fibers can range from about 1 to about 8. In otherembodiments, the denier of the fibers can range from about 1 to about 5.Additionally, in some embodiments, nonwovens of the present inventioncan comprise fibers made of polypropylene, polyethylene, polyolefins,bicomponent fibers, or any combination thereof

Additionally, crimped composite fiber (hereinafter simply referred to ascomposite fiber or a nonwoven fabric laminate made with same) can beused in accordance with the present invention. The crimped compositefiber may comprise a first propylene type polymer and a second propylenetype polymer. The first and second propylene type polymers can bearranged to occupy substantially separate areas at the cross sections ofthe composite fibers and extend continuously in the length direction. Insome embodiments, each of the first and second propylene type polymersform at least a part of the peripheral surface along the lengthdirection of the composite fiber. In some embodiments, as shown in FIG.9A, a composite fiber 1500 can be a side-by-side type composite fiberwhere a first propylene type polymer 1502 and a second propylene typepolymer 1510 extend side-by-side in the length direction of thecomposite fiber such that the first and the second propylene typepolymers 1502 and 1510 each form about 50% of a peripheral surface 1520of the composite fiber 1500.

The first propylene type polymer 1502 and the second propylene typepolymer 1510 can be arranged in any suitable configuration which wouldyield a crimp in the resulting fiber 1500. For example, in someembodiments, as shown in FIG. 9B, the second propylene type polymer 1510may form a cross like pattern within the first propylene type polymer1502 which is asymmetrically distributed within the first propylene typepolymer. In some embodiments, as shown in FIG. 9C, the second propylenetype polymer 1510 can be completely surrounded by the first propylenetype polymer 1502 such that the first propylene polymer 1502 comprisesabout 100% of the peripheral surface 1520 of the composite fiber 1500.The second propylene type polymer 1510 can be distributed within thefirst propylene type polymer 1502 asymmetrically such that a crimpresults in the resulting fiber 1500. In some embodiments, the firstpropylene type polymer 1502 and the second propylene type polymer 1510may be in a side-by side orientation such that an opening 1530 is formedbetween the first propylene type polymer and the second propylene typepolymer. This configuration can be similar to a hollow fiber.

Additionally, embodiments are contemplated where the second propylenetype polymer 1510 comprises any number greater than about 50% of theperipheral surface 1520 of the composite fiber 1500. Additionally,embodiments are contemplated where the second propylene type polymer1510 comprises any number less than about 50% of the peripheral surface1520 of the composite fiber 1500. Also, the first propylene type polymer1502 can be configured similarly to the second propylene type polymer1510 and vice versa. Embodiments are contemplated where fibers arecrimped such that they curl or form helical structures.

In some embodiments, the melting point of the first propylene typepolymer 1502 measured by differential scanning calorimetry (DSC) can beat least 15° C. higher than the melting point of the second propylenetype polymer 1510. In some embodiments, the melting point of the firstpropylene type polymer 1502 can be in a range of about 15 degrees C. toabout 60 degrees C., or any number within the range, higher than themelting point of the second propylene type polymer 1510.

Furthermore, the measured weight ratio of the first propylene typepolymer 1502 to the second propylene type polymer 1510 can be, in someembodiments, in the range of about 50/50 to about 5/95 or any ratiowithin the range. In some embodiments, the weight ratio can be in therange of about 40/60 to about 10/90 or any ratio within the range. Insome embodiments, the weight ratio can be in the range of about 30/70 toabout 10/90 or any ratio within the range.

In some embodiments, a possible method for determining the weight ratioof the first propylene type polymer 1502 to the second propylene typepolymer 1510 may be Temperature Rising Elution Fractionation (TREF). Forexample, using a Cross Fractionation Chromatograph T-150A manufacturedby Mitsubishi Chemicals Corporation; an IR spectrometer 1 ACVF 3.42micrometer at 135 degrees C., manufactured by Miran; and a TREF columnhaving an inner diameter of 4 mm and a length of 150 mm, the weightratios may be determined

Other steps may include, utilizing an eluent of o-dichlorobenzene (ODCB)at a flow rate of 1.0 mL/min, a concentration of sample of 30 mg/10mL-ODCB, and a sample volume of 500 micro liters. Yet other conditionsmay include cooling the sample from 135 degrees C. to 0 degrees C. in135 minutes and then holding the sample at 0 degrees C. for 60 minutes.Fractionation steps may include 0, 20, 40, 50, 60, 75, 80, 83, 86, 89,92, 95, 98, 101, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122, 125,130, and 135 degrees C.

A resulting elution curve can be divided by a perpendicular line(perpendicular to the x-axis) at a valley between two peaks. Theperpendicular line can create a first portion and a second portion ofthe elution curve. The first portion may comprise the area under thecurve to the right of the perpendicular line while the second portionmay comprise the area under the curve to the left of the perpendicularline. The weight ratio of the first propylene type polymer relative tothe second propylene type polymer may be calculated by a ratio firstportion to the second portion.

In some embodiments, the melt-flow rate of the first and secondpropylene type polymers measured according to the specification of ASTMD1238 (MFR: measuring temperature 230° C., load 2.16 kg) (secondpropylene type polymer/first propylene type polymer) can be in the rangeof about 0.8 to about 1.2 or any individual number within the range. Insome embodiments, the melt-flow rate can be in the range of about 0.9 toabout 1.1.

In some embodiments, the area ratio of the first propylene type polymerand the second propylene type polymer at the cross section of thecomposite fiber can be about the same as the weight ratio. For example,in some embodiments, a ratio of the cross sectional area of the firstpropylene type polymer to the cross sectional area of the secondpropylene type polymer can be in a range of about 50/50 to about 5/95 orany ratio within the range. In some embodiments, the ratio can be in therange of about 40/60 to about 10/90 or any ratio within the range. Insome embodiments, the ratio can be in the range of about 30/70 to about10/90 or any ratio within the range.

When the aforementioned condition is satisfied, a crimped state can beachieved in the composite fiber. A suitable number of crimps accordingto the specification of JIS L1015 can be in the range of about 5 crimpsto about 50 crimps/25 mm or any individual number within the range.

In the present invention, measurement of the melting point of the firstand second propylene type polymers based on DSC was done by aninstrument of the Perkin Elmer Corp. As the sample was set on ameasuring plate, the temperature was increased from 30° C. to 200° C. ata temperature increase rate of 10° C./min; 200° C. was retained for 10min; then, the temperature was reduced to 30° C. at a temperaturedecrease rate of 10° C./min; then, the temperature was again increasedfrom 30° C. to 200° C. at a temperature increase rate of 10° C./min andmeasurements were made on the second run.

Furthermore, it is desirable when two or more melting point peaks in thecomposite fiber exist based on DSC and the area of the lowest meltingpoint peak is greater than the area of the higher melting point peak.The measurement of the melting point of the composite fiber based on DSCwas done by the aforementioned device with the sample set on themeasuring plate as the temperature was increased from 30° C. to 200° C.at a temperature increase rate of 10° C./min, and the aforementionedmeasurement was made during the first run. In the aforementionedmeasurement method, the melting point is obtained as the peak on theendothermic curve and the area of the melting point peak can be obtainedalong with the value of the melting point. When two melting point peaksof the composite fiber obtained by the measuring method of the first runoverlap, the peak with an absence of other peaks is estimated accordingto the shape of the peak with maximum strength, and the area is obtainedand comparison is made with the area of the other peaks.

In regard to the first and second propylene type polymer comprising thecomposite fiber of the present invention, propylene homopolymer andcopolymers of propylene and one or more different types of α-olefinswith 2-20 carbon atoms, preferably, 2-8 carbon atoms such as ethylene,1-butene, 1-pentene, 1-hexene, 1-octene and 4-methyl-1-pentene, andhaving propylene as the primary structural unit can be utilized in someembodiments. Among those listed above, a propylene homopolymer orpropylene-ethylene random copolymer having an ethylene unit content inthe range of about 0 to about 10 mol % and MFR in the range of about 20to about 200 g/10 min is desirable.

In some embodiments, the first propylene type polymer can be a propylenehomopolymer and the second propylene type polymer can be a randomcopolymer of propylene and a small amount of ethylene having a uniformethylene component content in the range of about 10 mol % or below, andpreferably in the range of about 2 to about 10 mol %, from thestandpoint of production of a nonwoven fabric having excellent fasteningstrength and mechanical strength as well as high bulkiness and softnesssuitable for use as the female component of a fastening system. In thiscase, the amount of ethylene unit component is obtained according to astandard method using ¹³C-NMR spectral analysis.

In some embodiments, the melting point of the first propylene typepolymer can be in the range of about 120 to about 175° C., or anyindividual number within the range. In some embodiments, the meltingpoint of the second propylene type polymer can be in the range of about110 to about 155° C. The aforementioned propylene type polymers can beproduced utilizing a high stereospecific polymeric catalyst.

In addition to propylene type polymers, an appropriate amount of othercomponents may be included in the aforementioned composite fiber, asneeded, as long as the purpose of the present invention is not lost.Some examples of suitable other components may include: heatstabilizers, weather resistance agents, a variety of stabilizers,antistatic agents, slip agents, anti-blocking agents, antifoggants,lubricants, dyes, pigments, natural oils, synthetic oils, waxes, etc.Some suitable examples of stabilizers include, antioxidants such as2,6-di-t-butyl-4-methylphenol (BHT); phenolic antioxidants such astetrakis[methylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate]methane, β-(3,5-di-t-butyl-4-hydroxyphenyl)alkyl esterpropionate, and 2,2′-oxamidebis[ethyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate; fatty acid metal salts such as zinc stearate, calciumstearate, and calcium 1,2-hydroxystearate; polyhydric alcohol fatty acidesters such as glycidyl monostearate, glycidyl distearate,pentaerythritol monostearate, pentaerythritol distearate andpentaerythritol tristearate, etc. Furthermore, one or more differenttypes of the components may be mixed and used in combination as well.Some examples of suitable lubricants include oleic acid amide, erucicacid amide, stearic acid amide, etc.

Furthermore, in some embodiments, the composite fiber may furtherinclude fillers such as silica, diatomaceous earth, alumina, titaniumoxide, magnesium oxide, pumice powder, pumice balloon, aluminumhydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite,calcium sulfate, potassium titanate, barium sulfate, calcium sulfite,talc, clay, mica, asbestos, calcium silicate, montmorillonite,bentonite, graphite, aluminum powder, and molybdenum sulfide.

Mixing of propylene type polymer and the optional components mentionedabove can be achieved using any suitable conventional method.

Production of a spun-bonded nonwoven fabric can be achieved, in someembodiments, when the first propylene type polymer that forms one areaof the composite fiber and the second propylene type polymer that formsthe other area are melted by a separate extruder. The first propylenetype polymer and the second propylene type polymer can be extruded froma nozzle plate having a composite spinning nozzle structure in such amanner that each molten material can be extruded while forming a desiredfiber structure so as to extrude a composite long fiber. The long fiberextruded can be chilled by cooling air. In some embodiments, tension isapplied with blowing air to form a predetermined fiber size. The fibercan be collected as is on a collection belt to deposit to form apredetermined thickness, and for bonding treatment, thermal fusion canbe applied to the nonwoven fabric using embossing finish.

Where the nonwoven comprises bi-component fibers as described above, insome embodiments, the fiber size of the nonwoven fabric is preferably inthe range of about 0.5 to about 5.0 denier, or any individual numberwithin the range. In some embodiments, the fiber size can be in therange of about 1.0 to about 4.0 denier. The basis weight of the nonwovenfabric, in some embodiments, can be in the range of about 20 to about 80g/m², or any individual number within the range. In some embodiments,the basis weight can be in the range of about 30 to about 60 g/m².

A fastening system constructed in accordance with the present inventionmay be incorporated into a variety of consumer and commercial goods thatmay benefit from having a receiving component which comprises a bondpattern constructed in accordance with the present invention. In any ofthe embodiments described herein, the receiving component may be aseparate element added to the commercial good. For example, thereceiving member may be a discrete structure joined to any component(e.g., a topsheet, an absorbent core, a backsheet, a fastening system, aside panel, a cuff, etc.) of an absorbent article or other commercialgood (e.g., a wrap, a medical product, etc.). Alternatively, thereceiving component may be constructed as part or all of any element ofthe commercial good or fastener. For example, the receiving componentmay be constructed as part or all of any component (e.g., a topsheet, anabsorbent core, a backsheet, a fastening system, a side panel, a cuff,etc.) of an absorbent article or other commercial good (e.g., a wrap, amedical product, etc.). Further, receiving component may be disposed inany suitable location on or in the commercial good or fastener. Forexample, the receiving component may be disposed on a outer-facingsurface of, wearer-facing surface of, or contained within the commercialgood or fastener. For the sake of explanation, the receiving componentof the present invention will be discussed in the context of disposablediapers.

As shown in FIGS. 7A and 7B, a disposable absorbent article 600 maycomprise a liquid pervious topsheet 622 and a backsheet 624 joined to atleast a portion of the topsheet 622. The disposable absorbent article600 further comprises an absorbent core 646 positioned between thetopsheet 622 and the backsheet 624. The disposable absorbent article 600may further comprise side panels 628, outer cuffs 632, inner cuffs 652,and waist features 630.

A portion of the periphery of the disposable absorbent article 600 canbe defined by the longitudinal edges 675A and 675B; the first waist edge650, and the second waist edge 651. The longitudinal edges 675A and 675Bmay run generally parallel to a longitudinal centerline 690 of thedisposable absorbent article 600. The first waist edge 650 and thesecond waist edge 651 may run generally parallel to a lateral centerline680 of the disposable absorbent article 600. The disposable absorbentarticle 600 may further comprise elastic leg features 631 which can bedisposed adjacent to the longitudinal edges 675A and 675B.

The disposable absorbent article 600 may further comprise a first waistmember 602 and a second waist member 604. The first waist member 602and/or the second waist member 604 can be elastically extensible. Asshown, in some embodiments, the first waist member 602 can be disposedadjacent the first waist edge 650. In some embodiments, the second waistmember 604 can be disposed adjacent to the second waist edge 651.Generally, the first waist member 602 and/or the second waist member 604can be under tension prior to joining to the disposable absorbentarticle 600. So, upon release of at least a portion of the tensionapplied to the first waist member 602 and/or the second waist member604, a portion of the disposable absorbent article 600 joined theretocan corrugate. This corrugation of the disposable absorbent article 600can allow the first waist member 602 and/or the second waist member 604and the disposable absorbent article 600 to expand and contract aboutthe waist of a wearer, thereby providing more comfort and improved fitto a wearer. Examples of suitable waist members 602 and/or 604 includethose described in U.S. Pat. No. 4,515,595, U.S. Pat. No. 5,151,092, andU.S. Pat. No. 5,221,274. Although disposable diapers are generallyconstructed so as to have two elastic waist features, one positioned ina first waist region and one positioned in a second waist region,diapers can be constructed with a single elastic waist feature.

The disposable absorbent article 600 may further comprise outer cuffs632 and inner cuffs 652 to improve containment of liquids and other bodyexudates. Each elasticized outer cuff 632 may include several differentembodiments for reducing the leakage of body exudates in the legregions. Outer cuffs 632 and inner cuffs 652 are further described inU.S. Pat. No. 3,860,003; U.S. Pat. No. 4,909,803; and U.S. Pat. No.4,695,278.

As stated previously, the disposable absorbent article may furthercomprise a pair of side panels 628. As shown in FIG. 7B, the side panels628 can extend outward from the first longitudinal edge 675A and thesecond longitudinal edge 675B of the disposable absorbent article 600.In some embodiments, the side panels 628 can be joined to the disposableabsorbent article 600 in the second waist region 638, and in someembodiments, the side panels 628 can be joined to the disposableabsorbent article 600 in the first waist region 636. Alternatively, insome embodiments, the disposable absorbent article 600 may comprise apair of side panels which are disposed in the second waist region 638and a pair of side panels which are disposed in the first waist region636. In some embodiments, the side panels 628 can form a portion of theleg openings when the disposable absorbent article 600 is fastened. Theside panels 628 can form a portion of the leg openings which would bedisposed on an outer surface of a leg of a wearer. A crotch region 610of the disposable absorbent article 600 in conjunction with the firstwaist region 636 and the second waist region 638 can form a portion ofthe leg openings which would be disposed on an inner surface of the legof the wearer. In some embodiments, the side panels 628 can beelastically extensible.

The disposable absorbent article 600 further comprises a fasteningsystem 640 which joins at least a portion of a first waist region 636with at least a portion of a second waist region 638, preferably to formleg and waist openings. The fastening system 640 also works with thewaist members(s) 602 and/or 604 to maintain lateral tension in order tokeep the disposable absorbent article 600 in place about the waist ofthe wearer. The fastening system 640 may comprise engaging components642 which, in some embodiments, can be disposed on the side panels 628.The fastening system 640 may further comprise a receiving component 644which, in some embodiments, is disposed in the first waist region 636.

As shown in FIG. 7C, in other embodiments, the fastening system 640 caninclude a plurality of fastening components on the side panels 628. Forexample, as shown, the side panel 628 may comprise the engagingcomponent 642 which, in some embodiments, can include a plurality ofengaging elements. Additionally, in some embodiments, the side panel 628may further comprise a receiving component 1475 which is disposedopposite of the engaging component 642. One advantage of thisarrangement is that the engaging component 642 can engage the receivingcomponent 644 (shown in FIG. 7A) which is joined to the first waistregion 636 or can join to the receiving component 1475 of the other sidepanel 628.

As shown in FIG. 7A, the receiving component 644 is disposed on thedisposable absorbent article 600 such that the overlap of the bond lines1375 is generally perpendicular to the primary direction of shear 775.As shown in FIG. 7A, the primary direction of shear 775 is an expectedin use force which typically occurs once the disposable absorbentarticle 600 is in a fastened state. In some embodiments, the receivingcomponent 644 can be disposed adjacent the first waist edge 650 in thefirst waist region 636 on an outer-facing surface of disposableabsorbent article 600. In other embodiments, the receiving component 644can be disposed adjacent the second waist edge 651 in the second waistregion 638. In this embodiment, the engaging elements 642 can bedisposed adjacent the first waist region 636. In some embodiments,receiving components 644 can be disposed on the side panels 628 and theengaging component can be disposed in the first waist region 636. Insome embodiments, the receiving component 644 may comprise a pluralityof discrete elements.

Any suitable engaging element 642 can be used in the present invention.An example of a suitable engaging element 642 comprises hook fasteningmaterial. The hook fastening material can mechanically engage fibrouselements of the receiving element 644 so as to provide a secure closure.A hook fastening material according to the present invention may bemanufactured from a wide range of materials. Suitable materials includenylon, polyester, polypropylene, or any combination of these materials,or other materials as are known in the art.

A suitable hook fastening material comprises a number of shaped engagingelements projecting from a backing such as the commercially availablematerial designated Scotchmate™ brand No. FJ3402 available fromMinnesota Mining and Manufacturing Company, St. Paul, Minn.Alternatively, the engaging elements may have any shape such as hooks,“T's”, mushrooms, or any other shape as are well known in the art. Anexemplary hook fastening material is described in U.S. Pat. No.4,846,815. Another suitable hook fastening material comprises an arrayof prongs formed of thermoplastic material. Hot melt adhesivethermoplastics, in particular polyester and polyamide hot meltadhesives, are particularly well suited for forming the prongs of thehook fastening material. The prongs, in some embodiments, can bemanufactured using a modified gravure printing process by printing thethermoplastic material in its molten state onto a substrate in discreteunits, severing the material in a manner that allows stretching of aportion of the thermoplastic material prior to severance, and allowingthe stretched molten material to “freeze” resulting in prongs. This hookfastening material and methods and apparatus for making such a hookfastening material are more fully detailed in European PatentApplication 0 381 087.

The fastening system 640 may be the primary fastening system for joiningthe first and second waist regions 636 and 638. However, the fasteningsystem 640 may be used alone or in conjunction with other fasteningmeans such as tab and slot fasteners, tape fasteners, snaps, buttons,and the like to provide different fastening characteristics. Forexample, the fastening system 640 may provide the disposable absorbentarticle 600 with a disposal means for fastening the disposable absorbentarticle 600 in a configuration convenient for disposal. Further,secondary fastening means may provide the disposable absorbent article600 with a means for adjusting fit or may increase the strength of theconnection between the first waist region 636 and the second waistregion 638.

The fastening system 640 can be prefastened in a package such that acaregiver or wearer may pull on the disposable absorbent article 600when removed from the package. Alternatively, the fastening system 640can be unfastened in the package such that the caregiver or wearerfastens the fastening system 640 while donning the disposable absorbentarticle 600. In yet another embodiment, a package may comprise bothprefastened and unfastened disposable absorbent articles 600 for theconvenience of the caregiver or the wearer.

As shown in FIG. 8A, a disposable absorbent article 700 comprising afastening system 740 is shown. The fastening system 740 comprises afirst engaging component 760A disposed on a first side panel 728A and asecond engaging component 760B disposed on a second side panel 728B. Thefirst engaging component 760A and the second engaging component 760B canengage the receiving component 644 when fastened.

The receiving component 644 may comprise a plurality of bond lines 718created in accordance with the present invention. Each of the pluralityof bond lines 718 may comprise hills and valleys. As mentionedpreviously, the receiving component 644 can be disposed on thedisposable absorbent article 700 such that the overlap between the bondlines is generally perpendicular to the primary direction of shear 775.So, receiving components of the present invention constructed similar tothe receiving component 100 (shown in FIGS. 1B and 3) can be disposed onthe disposable absorbent article 700 such that the lateral axis 162(shown in FIGS. 1B and 3) of the receiving component is generallyparallel to the primary direction of shear 775.

Alternatively, receiving components of the present invention constructedsimilar to the receiving component 1000 (shown in FIG. 6) can bedisposed on the disposable absorbent article 700 such that thelongitudinal axis 1060 of the receiving component is generally parallelto the primary direction of shear 775.

The primary direction of shear 775 is defined by the in use forces.Specifically, when the disposable absorbent article 700 is in a fastenedstate, the first side panel 728A and the second side panel 728B exert aforce on the receiving component 644. The force can be caused, in part,by the elastomeric material of the side panels, if they are elasticallyextensible. Additionally, the shear forces may be caused by user orcaregiver during application of the disposable absorbent article 700.

As shown in FIG. 8B, a disposable absorbent article 702 comprising afastening system 740 is shown. Similar to the disposable absorbentarticle above, the first engaging component 760A and the second engagingcomponent 760B can engage the receiving component 644 when fastened. Thereceiving component 644 may comprise a first plurality of bond lines 722and a second plurality of bond lines 720. A portion of each of the firstplurality of bond lines 722 overlaps a portion of each adjacent bondline. Similarly, a portion of each of the second plurality of bond lines720 overlaps a portion of each adjacent bond line.

The first plurality of bond lines 722 may be angled such that they canprovide a visual signal to a wearer of where to fasten the firstengaging component 760A. Additionally, the second plurality of bondlines 720 may be angled such that they can provide a visual signal to awearer of where to fasten the second engaging component 760B.

In some embodiments, the fastening angles 1250 can be in a range frombetween about 0 degrees to about 45 degrees or any individual numberwithin that range. In other embodiments, the fastening angle 1250 can bebetween about 10 degrees and about 25 degrees. In yet other embodiments,the fastening angle 1250 can be between about 15 degrees and about 20degrees.

The fastening angle 1250 of the first plurality of bond lines 722 can bedetermined by performing straight line approximations for each of thebond lines within bond pattern of the first plurality of bond lines 722.A bond line can be considered to be a part of the first plurality ofbond lines 722 if a portion of that bond line overlaps any portion ofanother bond line within the first plurality of bond lines 722. Thestraight line approximations for each of the bond lines within the firstplurality of bond lines 722 can be averaged to determine a firstorientation line 1253 for the first plurality of bond lines 722. Theintersection between the first orientation line 1253 and a longitudinalaxis 770 of the disposable absorbent article 702 defines the fasteningangle 1250. The same analysis can be performed for the second pluralityof bond lines 720.

Disposable absorbent articles may comprise many components, elements,members, etc. and can be constructed in a variety of manners. Forexample, the topsheet 622 (shown in FIG. 6) and the backsheet 624 (shownin FIG. 6) can have length and width dimensions generally larger thanthose of the absorbent core 626 (shown in FIG. 6). The topsheet 622(shown in FIG. 6) and the backsheet 624 (shown in FIG. 6) can extendbeyond the edges of the absorbent core 626 (shown in FIG. 6), therebyforming the periphery of the disposable absorbent article 600 (shown inFIG. 6). The topsheet 622 (shown in FIG. 6), the backsheet 624 (shown inFIG. 6), and the absorbent core 626 (shown in FIG. 6) may include manydifferent materials and may be assembled in a variety of well knownconfigurations, exemplary diaper materials and configurations aredescribed generally in U.S. Pat. No. 3,860,003, U.S. Pat. No. 5,151,092,and U.S. Pat. No. 5,221,274.

Any topsheet compatible with the present invention which is known in theart can be used in the present invention. A suitable material for atopsheet may be manufactured from a wide range of materials, such asporous foams, reticulated foams, apertured plastic films, or woven ornonwoven materials of natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester or polypropylene fibers), or acombination of natural and synthetic fibers. As an example, a materialsuitable for use in a topsheet comprises a web of staple-lengthpolypropylene fibers is manufactured by Veratec, Inc., a Division ofInternational Paper Company, of Walpole, Mass. under the designationP-8.

Some examples of suitable topsheets are described further in U.S. Pat.No. 3,929,135; U.S. Pat. No. 4,324,246; U.S. Pat. No. 4,342,314; U.S.Pat. No. 4,463,045; U.S. Pat. No. 5,006,394; U.S. Pat. No. 4,609,518;U.S. Pat. No. 4,629,643. Any portion of the topsheet may be coated witha lotion as is known in the art. Examples of suitable lotions includethose described in U.S. Pat. No. 5,607,760; U.S. Pat. No. 5,609,587;U.S. Pat. No. 5,635,191; U.S. Pat. No. 5,643,588; U.S. Pat. No.5,968,025; U.S. Pat. No. 6,716,441; and PCT Publication No. WO 95/24173.

Further, the topsheet may be fully or partially elastically extensibleor may be foreshortened so as to provide a void space between thetopsheet and the absorbent core. Exemplary structures includingelasticized or foreshortened topsheets are described in more detail inU.S. Pat. No. 4,892,536; U.S. Pat. No. 4,990,147; U.S. Pat. No.5,037,416; and U.S. Pat. No. 5,269,775.

A suitable backsheet for use in the disposable absorbent article of thepresent invention may comprise a laminated structure. For example, aspreviously discussed, the backsheet may comprise a first backsheet layerand a second backsheet layer (see items 241 and 242 of FIG. 2C). Thesecond backsheet layer can be impervious to liquids (e.g., urine) andcomprise a thin plastic film such as a thermoplastic film having athickness, for example, of about 0.012 mm (0.5 mils) to about 0.051 mm(2.0 mils). Suitable backsheet films include those manufactured byTredegar Corporation, based in Richmond, Va., and sold under the tradename CPC2 film. Either the first backsheet layer and/or the secondbacksheet layer may include breathable materials which permit vapors toescape from the pull-on garment while still preventing exudates frompassing through the backsheet. Suitable breathable materials may includematerials such as woven webs, nonwoven webs, composite materials such asfilm-coated nonwoven webs, microporous films such as manufactured byMitsui Toatsu Co., of Japan under the designation ESPOIR NO and byTredegar Corporation of Richmond, Va. and sold under the designationEXAIRE, and monolithic films such as manufactured by Clopay Corporation,Cincinnati, Ohio under the name HYTREL blend P18-3097. Some breathablecomposite materials are described in greater detail in PCT ApplicationNo. WO 95/16746; U.S. Pat. No. 5,938,648; U.S. Pat. No. 5,865,823; andU.S. Pat. No. 5,571,096.

The backsheet, or any portion thereof, may be elastically extensible inone or more directions. In one embodiment, the backsheet may comprise astructural elastic-like film (“SELF”) web. A structural elastic-likefilm web is an extensible material that exhibits an elastic-likebehavior in the direction of elongation without the use of added elasticmaterials and is described in more detail in U.S. Pat. No. 5,518,801. Inalternate embodiments, the backsheet may comprise elastic films, foams,strands, or combinations of these or other suitable materials withnonwovens or synthetic films.

A suitable absorbent core for use in the present invention may compriseany absorbent material which is generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudates. Inaddition, the configuration and construction of the absorbent core mayalso be varied (e.g., the absorbent core(s) or other absorbentstructure(s) may have varying caliper zones, hydrophilic gradient(s), asuperabsorbent gradient(s), or lower average density and lower averagebasis weight acquisition zones; or may comprise one or more layers orstructures). Suitable exemplary absorbent structures for use as theabsorbent core are described in U.S. Pat. No. 4,610,678; U.S. Pat. No.4,673,402; U.S. Pat. No. 4,834,735; U.S. Pat. No. 4,888,231; U.S. Pat.No. 5,137,537; U.S. Pat. No. 5,147,345; U.S. Pat. No. 5,342,338; U.S.Pat. No. 5,260,345; U.S. Pat. No. 5,387,207; and U.S. Pat. No.5,625,222.

The backsheet may be joined to the topsheet, the absorbent core, or anyother element of the disposable absorbent article by any attachmentmeans known in the art. For example, the attachment means may include auniform continuous layer of adhesive, a patterned layer of adhesive, oran array of separate lines, spirals, or spots of adhesive. Some suitableattachment means are disclosed in U.S. Pat. No. 4,573,986; U.S. Pat. No.3,911,173; U.S. Pat. No. 4,785,996; and U.S. Pat. No. 4,842,666.Examples of suitable adhesives are manufactured by H. B. Fuller Companyof St. Paul, Minn. and marketed as HL-1620 and HL-1358-XZP.Alternatively, the attachment means may comprise heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment means or combinations of these attachment means as are knownin the art.

Various sublayers may be disposed between the topsheet and thebacksheet. The sublayer may be any material or structure capable ofaccepting, storing or immobilizing bodily exudates. Thus, the sublayermay include a single material or a number of materials operativelyassociated with each other. Further, the sublayer may be integral withanother element of the pull-on disposable absorbent article or may beone or more separate elements joined directly or indirectly with one ormore elements of the disposable absorbent article. Further, the sublayermay include a structure that is separate from the absorbent core or mayinclude or be part of at least a portion of the absorbent core.

Suitable exemplary materials for use as the sublayer may include largecell open foams, macro-porous compression resistant nonwoven highlofts,large size particulate forms of open and closed cell foams (macro and/ormicroporous), highloft nonwovens, polyolefin, polystyrene, polyurethanefoams or particles, structures comprising a multiplicity of verticallyoriented looped strands of fibers, absorbent core structures describedabove having punched holes or depressions, and the like. (As usedherein, the term “microporous” refers to materials which are capable oftransporting fluids by capillary action. The term “macroporous” refersto materials having pores too large to effect capillary transport offluid, generally having pores greater than about 0.5 mm in diameter and,more specifically, having pores greater than about 1.0 mm in diameter.)One embodiment of a sublayer includes a mechanical fastening looplanding element, having an uncompressed thickness of about 1.5millimeters available as XPL-7124 from the 3M Corporation ofMinneapolis, Minn. Another embodiment includes a 6 denier, crimped andresin-bonded nonwoven highloft having a basis weight of 110 grams persquare meter and an uncompressed thickness of 7.9 millimeters which isavailable from the Glit Company of Wrens, Ga. Other suitable absorbentand nonabsorbent sublayers are described in U.S. Pat. No. 6,680,422 andU.S. Pat. No. 5,941,864. Further, the sublayer, or any portion thereof,may include or be coated with a lotion or other known substances to add,enhance or change the performance or other characteristics of theelement.

Embodiments of the present invention may also include pockets forreceiving and containing waste, spacers which provide voids for waste,barriers for limiting the movement of waste in the article, compartmentsor voids which accept and contain waste materials deposited in thepull-on disposable absorbent article, and the like, or any combinationsthereof. Examples of pockets and spacers for use in absorbent productsare described in U.S. Pat. No. 5,514,121; U.S. Pat. No. 5,171,236; U.S.Pat. No. 5,397,318; U.S. Pat. No. 5,540,671; U.S. Pat. No. 6,168,584;U.S. Pat. No. 5,306,266; and U.S. Pat. No. 5,997,520. Examples ofcompartments or voids in an absorbent article are disclosed in U.S. Pat.No. 4,968,312; U.S. Pat. No. 4,990,147; U.S. Pat. No. 5,062,840; andU.S. Pat. No. 5,269,755. Examples of suitable transverse barriers aredescribed in U.S. Pat. No. 5,554,142; PCT Patent WO 94/14395; and U.S.Pat. No. 5,653,703. Examples of other structures suitable for managementof low viscosity feces are disclosed in U.S. Pat. No. 5,941,864; U.S.Pat. No. 5,977,430; and U.S. Pat. No. 6,013,063.

Embodiments of the present invention may includeacquisition/distribution layers which can be configured to distributemoisture from a wetness event to moisture responsive members within thedisposable absorbent article. Examples of suitableacquisition/distribution layers are described in U.S. Pat. No.5,460,622, U.S. Patent Application Publication No. 2005/0027267, andU.S. Patent Application Publication No. 2005/009173.

Embodiments of the present invention may include a dusting layer whichis well known in the art. Examples of suitable dusting layers arediscussed in U.S. Pat. No. 4,888,231.

Test Methods: Determining the Bonded Area of a Receiving Component:Sample Preparation

1. Enough representative absorbent articles are selected from the retailpackaging of the absorbent article to conduct all required tests. Thereceiving components of each of the absorbent articles are removed fromthe articles. Suitable methods include cutting the receiving componentsoff of the articles.2. Each sample is allowed to equilibrate in a controlled environment.The environmental parameters are 22 degrees C.±2 degrees C., 50%Relative Humidity±10% Relative Humidity. Samples are placed in theseconditions at least 24 hours prior to testing.3. Secure a sample to a flat surface. The sample is secured to the flatsurface such that the sample is completely disposed on the flat surface.The sample is secured to the flat surface using tape such as ScotchRemovable Magic Tape™ manufactured by 3M™.4. Identify the bond zone in accordance with the description of the bondzone described herein.5. Identify the sweep regions within the bond zone in accordance withthe description of the sweep regions described herein. Each of the sweepregions has a length which is equal to the contact area between thecalendering rolls. Each of the sweep regions has a width which is equalto the width of the web the receiving component is produced on. Wherethe contact area between the calendering rolls is unavailable, dividethe length of the bond zone by 0.25 and round up to the nearest wholenumber. The quotient is the number of sweep regions within the bondzone. The sweep regions have an equal lengths.6. Measure the area bonded within each sweep region, and record thesweep region bonded areas as Bi, where i=1 to n with n being the totalnumber of sweep regions. The bonded area is measured to the nearest 0.01mm²7. Measure the total area of each sweep region, and record the totalsweep region area Si, where i=1 to n with n being the total number ofsweep regions. The total area is measured to the nearest 0.01 mm²8. From the data collected, calculate:

a) Bond Ratio:

-   -   i) Identify the sweep region having the smallest bond area,        record as Bi,min.    -   ii) Identify the sweep region having the largest bond area,        record as Bi,max.    -   iii) Calculate the Bond Ratio=Bi,max/Bi,min.

b) % Bonded Area in each Sweep Region:

-   -   i) Percent Bonded area for each sweep region=100*Bi/Si.

c) Overall % Bonded Area:

-   -   i) Calculate cumulative bonded area, Bt=sum of Bi, where i=1 to        n.    -   ii) Calculate cumulative total area, St=sum of Si, where i=1 to        n.    -   iii) Overall Percent Bonded Area=100*Bt/St.

As stated previously, the areas may be measured using straight-linemeasures and geometric/trigonometric relationships. Alternatively,computerized image analysis may be used for more complex bond linepatterns.

Determining the Number of Crimps in a Fiber:

Number of crimps was measured according to the procedure explainedbelow. It should be noted that with the exception of the procedure shownbelow, measurements were done according to the specification of JISL1015.

First, lines with a spatial separation of 25 mm were formed on a pieceof glossy paper with a smooth surface. The two ends of each fiber werecarefully removed from the nonwoven fabric prior to thermal compressiontreatment by an embossing roll such that crimping was not lost and wereapplied onto the aforementioned paper with a relaxation of 25±5% for thespatial separation.

The aforementioned each test piece was applied to the chuck of thecrimping tester, the paper was removed, and the distance between chucks(spatial distance) (mm) during the initial load (0.18 mN×displayed texnumber) was read.

The number of crimps at the time was counted and the number of crimpsper distance of 25 mm was obtained and the mean value of 20 times wasused. The number of crimps was obtained as the total peaks and valleyswere counted and divided by 2.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A fastening system comprising: an engagingcomponent comprising engaging elements; and a receiving componentconfigured to be engaged by a plurality of the engaging elements, thereceiving component comprising: a lateral axis; a longitudinal axis; anonwoven web comprising nylon, wherein a layer of the nonwoven webcomprises a portion comprising side-by-side composite fibers; a firstbond line and a second bond line in the nonwoven web and extending in afirst direction, wherein the second bond line is disposed adjacent tothe first bond line; a bond zone in the nonwoven web circumscribing thefirst bond line and the second bond line; and a plurality of consecutivesweep regions disposed within the bond zone, each sweep regioncomprising a length and a width, wherein lengths of the sweep regionsare equal and are generally parallel to the longitudinal axis, whereinthe widths of the sweep regions are equal and are generally parallel tothe lateral axis, wherein at least one sweep region comprises a portionof both the first bond line and the second bond line, wherein theremaining sweep regions of the plurality of sweep regions comprise atleast a portion of the first bond line or at least a portion of thesecond bond line, wherein the receiving component has a bond ratiobetween two sweep regions which is greater than about 1, and wherein theoverall bonded area of the receiving component is less than about 40%.2. The fastening system of claim 1, wherein a portion of the second bondline overlaps a portion of the first bond line.
 3. The fastening systemof claim 1, wherein the nonwoven web comprises a plurality of layers. 4.The fastening system of claim 1, wherein the nonwoven web comprisespolyolefins.
 5. The fastening system of claim 1, wherein the nonwovenweb comprises a layer of spunbond fibers.
 6. The fastening system ofclaim 1, wherein the side-by-side composite fibers comprise crimpedcomposite fibers.
 7. The fastening system of claim 1, wherein thereceiving component is a separate element and is joined to a portion ofa consumer good.
 8. The fastening system of claim 1, wherein thereceiving component is integrally formed with a portion of a consumergood.
 9. A fastening system comprising: an engaging component comprisingengaging elements; and a receiving component, wherein a plurality of theengaging elements are configured to engage the receiving component,wherein the receiving component comprises a nonwoven web comprisingnylon, and wherein a portion of the nonwoven web comprises side-by-sidecomposite fibers.
 10. The fastening system of claim 9, wherein theside-by-side composite fibers comprise crimped composite fibers.
 11. Thefastening system of claim 9, wherein the nonwoven web comprises a firstbond line and a second bond line disposed adjacent to the first bondline, and wherein a portion of the second bond line overlaps a portionof the first bond line.
 12. The fastening system of claim 9, wherein thereceiving component is a separate element and is joined to a portion ofa consumer good.
 13. The fastening system of claim 9, wherein thereceiving component is integrally formed with a portion of a consumergood.
 14. A fastening system comprising: an engaging componentcomprising engaging elements; and a receiving component, wherein aplurality of the engaging elements are configured to engage thereceiving component, and wherein the receiving component comprises: anonwoven web comprising nylon and side-by-side composite fibers; a firstbond line formed in the nonwoven web; and a second bond line formed inthe nonwoven web, wherein the first and second bond lines extend in afirst direction and are disposed adjacent to each other, and wherein thespacing between the first and second bond lines is about 1 mm to about20 mm.
 15. The fastening system of claim 14, wherein the nonwoven webcomprises one or more layers.
 16. The fastening system of claim 14,wherein the side-by-side composite fibers comprise crimped compositefibers.
 17. The fastening system of claim 14, wherein the nonwoven webcomprises a layer of spunbond fibers.
 18. The fastening system of claim14, wherein each of the bond lines have a thickness of about 0.5 mm toabout 2 mm.
 19. The fastening system of claim 14, wherein the nonwovenweb comprises fiber to fiber bond sites with portions comprisingaesthetic designs.